Method and apparatus for underwater pile excavating

ABSTRACT

An encapsulated underwater excavation assembly for removing solid materials (such as mud, soil, vegetation or debris) from a water bottom including, without limitation, during pile driving or installation operations. The excavation assembly can be contained within a housing that beneficially fits within an inner bore of a piling or other tubular member. A rotary motor having a cutting blade mechanically cuts solid materials while a centrifugal pump moves cuttings away from the lower portion of the excavation assembly for facilitate efficient installation of a piling.

CROSS REFERENCES TO RELATED APPLICATION

Priority of united states provisional patent application Ser. No. 61/843,552, filed Jul. 8, 2013, incorporated herein by reference, is hereby claimed.

STATEMENTS AS TO THE RIGHTS TO THE INVENTION MADE UNDER FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT

None

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention pertains to a method and apparatus for removing solid material, typically from an internal bore of a piling or other tubular member. More particularly, the present invention pertains to an excavating assembly employed to excavate and remove solid matter (including, without limitation, earth) from a piling below the surface of a body of water.

2.Brief Description of the Prior Art

It is frequently beneficial to excavate the bed of a body of water by mechanically removing mud, vegetation, rubbish and/or other debris using a dredge assembly. Although the applications for dredging are too numerous to list, dredging is frequently employed in connection with the offshore oil and gas industry and/or operations in support thereof. Frequently, such dredging or other excavation activities are performed in or around pilings that are driven or otherwise inserted into such a bed or water bottom.

In many instances, it is beneficial to excavate or otherwise remove mud, vegetation, rubbish and/or debris from an internal bore of a piling or section of pipe to assist with a pile driving or other installation process. Removal of such material generally permits a piling to be installed deeper and/or more efficiently than conventional pile driving operations. However, the space within an internal bore of a piling is typically severely restricted, which significantly limits the ability of conventional dredging/excavating systems to remove such material from such space.

Thus, there is a need for an effective excavating tool that can efficiently remove earth, mud, debris and other materials from an underwater environment including, without limitation, from an internal bore of a pile being driven or otherwise installed in a bed of a body of water. Such dredging tool should be capable of working within relatively confined spaces and should be more effective than conventional excavating tools.

SUMMARY OF THE INVENTION

The method and apparatus of the present invention can excavate or remove mud, vegetation, debris or other material from the bed of a body of water including, without limitation, from the interior of a pile, construction pipe or other tubular member that is driven, hammered or otherwise inserted into such a bed.

In a preferred embodiment, the pile excavating assembly of the present invention comprises an external housing containing a radial piston motor, which drives a cutter blade disposed at or near the bottom or distal end of said housing. Said housing also contains an axial piston motor, which drives a centrifugal pump used to pump cuttings and other solid materials through an outlet or discharge port disposed at or near the upper or proximate end of said housing.

The pile excavating assembly of the present invention further comprises a fluid control system. Said fluid control system, typically a hydraulic power system, can be driven either by a diesel or electric prime mover that operates a hydraulic fluid pump. In a preferred embodiment, said hydraulic fluid pump is located at or near the surface of the water. A plurality of hoses or other conduits, typically connected to a reel or spool, extend from said pump to said pile excavating assembly. Said pile excavating assembly is typically lowered to a submerged or partially submerged pile, pipe or other tubular that is being installed into the bed of a body of water.

Control fluid (typically hydraulic oil) is directed to and powers said at least two motors that are mounted within the housing of said cutting assembly. Said cutting assembly can be lowered into a pipe, piling or other tubular member using a crane or other lifting means.

BRIEF DESCRIPTION OF DRAWINGS/FIGURES

The foregoing summary, as well as any detailed description of the preferred embodiments, is better understood when read in conjunction with the drawings and figures contained herein. For the purpose of illustrating the invention, the drawings and figures show certain preferred embodiments. It is understood, however, that the invention is not limited to the specific methods and devices disclosed in such drawings or figures.

FIG. 1 depicts a side view of a pile excavating assembly of the present invention during excavating operations.

FIG. 2 depicts a partial cut away side view of a pile excavating assembly of the present invention disposed within a pile.

FIG. 3 depicts a side sectional view of a pile excavating assembly of the present invention.

FIG. 4 depicts a hydraulic control circuit of the present invention.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT

FIG. 1 depicts a side view of pile installation operations using a pile excavating assembly of the present invention. As depicted in FIG. 1, floating vessel 10 is deployed at surface 20 of a body of water such as, for example, a lake, ocean or gulf. Substantially tubular pile 200 having upper end 201 and a central through bore is oriented substantially vertically, and is depicted being installed into water bottom 40. During such installation operations, pile 200 must penetrate mud, soil, rock or other material comprising water bottom 40.

It is to be observed that pile 200 can be driven or hammered into water bottom 40 using pile installation technology (such as hammers or the like) well known to those having skill in the art, but which are not depicted in FIG. 1. Further, as depicted in FIG. 1, upper end 201 of pile 200 is positioned below water surface 20; however, it is to be observed that said upper end 201 of pile 200 can also extend above water surface 20 without departing from the scope of the present invention.

A pile excavating assembly of the present invention is suspended from a lifting apparatus 30 having boom 31, and is disposed within an inner bore of pile 200 and is therefore obscured from view in FIG. 1. As depicted in FIG. 1, said lifting apparatus 30 comprises a crane deployed on vessel 10, although a lifting apparatus other than a crane can be used without departing from the scope of the present invention. Said lifting assembly 30 supports an excavating assembly which is disposed within the inner bore of pile 200 using support cables 107. Flexible conduit casing 130, containing at least one control fluid conduit, extends from vessel 10 to said excavating assembly disposed within the inner bore of pile 200.

FIG. 2 depicts a partial cut away side view of pile excavating assembly 100 of the present invention suspended within a central bore of tubular pile 200. Pile excavating assembly 100 of the present invention comprises an external housing 101 having an upper or proximate end 102, as well as a lower or distal end 103. Although external housing 101 can have other shapes or configurations, in a preferred embodiment said housing 101 is substantially cylindrical in shape, defines an internal chamber, and has an outer diameter that is less than the inner diameter of an inner bore of pile 200.

As depicted in FIG. 2, a plurality of lifting pad-eye members 106 are attached to housing 101, and provide attachment points for cables 107 used to raise and lower excavating assembly 100 within the inner bore of tubular pile 200. Although not depicted in FIG. 2, it is to be observed that said cables 107 can extend to a lifting apparatus deployed at the water surface, such as lifting apparatus 30 disposed on vessel 10 shown in FIG. 1.

Said housing 101 further at least partially contains cutting blade 104; in a preferred embodiment, said cutting blade 104 partially protrudes or extends outward from lower end 103 of housing 101. Said cutting blade 104 includes abrasive teeth 105 disposed on at least one outer surface of said cutting blade 104. It is to be observed that the precise design of said teeth 105 on said cutting blade 104 can be modified to meet anticipated operational conditions or characteristics. By way of illustration, but not limitation, the placement, shape, geometry and/or configuration of said teeth 105 can be adjusted depending upon the soil characteristics of a water bottom to be excavated. Optional protective conduit casing 130, containing individual control fluid hoses or conduits, extends from said excavating assembly 100, which is disposed within the inner bore of pile 200, to a vessel 10 (not depicted in FIG. 2).

FIG. 3 depicts a side sectional view of pile excavating assembly 100 of the present invention. Said pile excavating assembly 100 of the present invention comprises an external housing 101 containing cutting motor 110. In a preferred embodiment, said cutting motor 110 comprises a radial piston motor having a drive shaft 111 oriented substantially perpendicular to the longitudinal axis of said excavating assembly 100. In most applications, said drive shaft 111 is oriented substantially horizontally, because excavating assembly 100 is oriented substantially vertically within a substantially vertical pile 200.

Cutting blade 104 having a plurality of cutting teeth 105 is disposed on said drive shaft 111. When cutting motor 110 is actuated, drive shaft 111 rotates, thereby causing cutting blade 104 to rotate about an axis passing through said drive shaft 111. In a preferred embodiment, said cutting blade 104 is beneficially positioned so that a portion of said cutting blade 104 protrudes or extends outward from lower end 103 of housing 101.

Pump motor 120 is mounted within housing 101; in a preferred embodiment, said pump motor 120 comprises an axial piston motor. Said pump motor 120 powers centrifugal pump 121 having pump inlet 122 and pump discharge port 123. Pump 121 is used to propel cuttings, solid materials and fluids including, without limitation, solid cuttings or soil broken loose by cutting blade 104. Such materials enter pump 120 through pump inlet 122, and exit pump 120 through discharge port 123, which can be beneficially positioned at or near the upper end 102 of housing 101.

The excavating assembly of the present invention further comprises a fluid-powered control system. Referring back to FIG. 1, in a preferred embodiment, said fluid control system comprises a hydraulic power system driven either by a prime mover 131 (typically either diesel or electrically powered engine) that powers a hydraulic fluid pump 132. Said prime mover 131 and hydraulic fluid pump 132 are located at or near water surface 20, typically on vessel 10. A plurality of hoses or other conduits, typically connected to a reel or spool positioned near said pump 132 and contained within a protective outer casing 130, extend from said pump 132 to an excavating assembly (such as excavating assembly 100 depicted in FIG. 3) disposed within pile 200.

Referring to FIG. 3, control fluid (typically hydraulic oil) is directed to and powers motors 110 and 120 mounted within external housing 101 of said excavating assembly 100. Said control fluid flows to and from said motors via separate hydraulic control lines or hoses 133 which, in turn, can be enclosed within protective conduit casing 130.

As noted above, control fluid (typically hydraulic oil) is directed to at least two hydraulic motors disposed within external housing 101 of excavating assembly 100 of the present invention. Said excavating assembly 100 can be lowered into the inner bore of a tubular pile member (such as pile 200 depicted in FIG. 1). A first hydraulic motor 110 with a cutting blade 104 loosens soil, mud or other debris that is encountered within said inner bore of said pile. A second hydraulic motor 120 operates a centrifugal pump 121 that discharges cuttings (and associated liquids) through discharge port 123. It is to be observed that a hose or other conduit can be used to connect to said discharge port 123 to facilitate pumping such excavated material out of the central bore of pile 200 through upper end 201.

FIG. 4 depicts a representative hydraulic control circuit 140 of the present invention. As depicted in FIG. 1, hydraulic control fluid is pumped via pump 132 driven by a diesel/hydraulic or electrical power source (prime mover) 131 producing a sufficient flow of hydraulic fluid through various control lines 133. Referring to FIG. 4, said hydraulic fluid flow can be provided through supply line 145 and beneficially divided at or near the excavation assembly using flow control valves 141, with a portion of such flow (typically half) directed to axial piston pump motor 120 (that operates a centrifugal pump), and the other portion of such flow (again, typically half) being directed to radial piston motor 110 (that drives a cutter head).

In a preferred embodiment, hydraulic circuit 140 includes relief valve 142 that is plumbed across input line 143 to return line 144. Said relief valve 142 provides added safety in the event that cutting blade 104 attached to radial piston motor 110 (depicted in FIG. 3) becomes stuck or encounters a stall from wedging against a foreign object. In such an event, hydraulic fluid flow is diverted around hydraulic motor 110 and is plumbed back through return line 144 connected to a hydraulic fluid reservoir at or near surface pump 132 (depicted in FIG. 1).

In operation, excavating assembly 100 can be suspended from a crane or other lifting apparatus and inserted within the internal bore of a pile, construction pipe or other tubular member that is driven, hammered or otherwise installed into a water bottom. Said excavating assembly is lowered within said bore until it makes contact with said water bottom. Hydraulic control fluid powers a rotating cutting blade which cuts or digs into said water bottom in order to excavate or loosen mud, vegetation, debris or other material from said water bottom. Such loosened material is directed to a pump in said excavating assembly and pumped out of the internal bore of said pile, thereby allowing said pile to penetrate into said water bottom deeper and more efficiently than conventional installation means. Said excavating assembly can be raised or lowered within said bore as needed.

The above-described invention has a number of particular features that should preferably be employed in combination, although each is useful separately without departure from the scope of the invention. While the preferred embodiment of the present invention is shown and described herein, it will be understood that the invention may be embodied otherwise than herein specifically illustrated or described, and that certain changes in form and arrangement of parts and the specific manner of practicing the invention may be made within the underlying idea or principles of the invention. 

What is claimed:
 1. An excavation apparatus for excavating solid materials from an inner bore of a piling comprising: a) a drive motor; b) a cutting blade connected to said drive motor adapted to contact said solid materials; and c) a pump for pumping said solid materials away from said excavation apparatus.
 2. The excavation apparatus of claim 1, further comprising a hydraulic control system.
 3. The excavation apparatus of claim 1, further comprising an outer housing defining an internal chamber.
 4. The excavation apparatus of claim 3, wherein said drive motor and pump are disposed in said internal chamber of said housing.
 5. The excavation apparatus of claim 4, wherein said cutting blade is partially disposed within said internal chamber of said housing, and a portion of said blade protrudes from said housing.
 6. The excavation apparatus of claim 1, wherein said excavation apparatus can be selectively raised or lowered within said inner bore of said pile.
 7. An excavation apparatus for excavating solid materials from an inner bore of a piling comprising: a) an outer housing defining an internal chamber; b) a drive motor disposed within said internal chamber; c) a pump motor disposed within said internal chamber; d) a pump for pumping said solid materials away from said excavation apparatus; and e) a cutting blade connected to said drive motor, wherein said cutting blade is adapted to contact said solid materials.
 8. The excavation apparatus of claim 7, further comprising a hydraulic control system for powering said drive motor and pump motor.
 9. The excavation apparatus of claim 7, wherein said cutting blade is partially disposed within said internal chamber of said housing, and a portion of said blade protrudes from said housing.
 10. A method for removing solid materials from an inner bore of a piling comprising: a) lowering an excavation apparatus within said bore until said excavation assembly contacts said solid materials; b) excavating said solid materials from said inner bore; and c) pumping said excavated solid materials from said inner bore.
 11. The method of claim 10, wherein said excavation apparatus comprises: a) an outer housing defining an internal chamber; b) a drive motor disposed within said internal chamber; c) a pump motor disposed within said internal chamber; d) a pump for pumping said solid materials away from said excavation apparatus; and e) a cutting blade connected to said drive motor, wherein said cutting blade is adapted to contact said solid materials.
 12. The method of claim 11, wherein said excavation apparatus further comprises a hydraulic control system for powering said drive motor and pump motor.
 13. The method of claim 12, wherein said cutting blade is partially disposed within said internal chamber of said housing, and a portion of said blade protrudes from said housing.
 14. The method of claim 10, wherein said excavation apparatus is suspended from a lifting apparatus deployed on a floating vessel.
 15. The method of claim 10, wherein said lifting apparatus comprises a crane. 